Patterned Tampon

ABSTRACT

A tampon including a compressed pledget of absorbent material. The tampon has a body portion and a longitudinal axis, wherein the tampon includes at least one patterned impression with one or more design elements oriented substantially perpendicular to the longitudinal axis, wherein at least one design element is formed by contact with at least one corresponding pattern including at least one lead in portion. An apparatus for making the tampon is also disclosed.

FIELD OF THE INVENTION

The invention relates to improved tampons and to apparatuses for makingsuch tampons.

BACKGROUND OF THE INVENTION

Tampons are generally compressed absorbent structures typically shapedand sized to fit into a body cavity, such as, for example a humanvagina. Often, due to the processes used for making tampons, the outersurface of the tampon, including the outer surface of the insertion end,the withdrawal end and/or the main body, may be relatively rough,uneven, crenulated, and unattractive. Such characteristics in thesurface topography of a tampon may provide the user with a negativeimpression of the product, especially when seen prior to use. Forexample, the insertion end of a tampon is often visible to a user priorto application, such as, e.g., with a digital tampon and/or a tamponprovided in an applicator that at least partially displays the outersurface of the tampon. Furthermore, surface topography of tampons, suchas, e.g., the insertion end, may affect tampon performance, such as, forexample, fluid absorption characteristics and/or user comfort duringinsertion.

Accordingly, it may be desirable to provide tampons that have arelatively attractive surface, such as the insertion end, withdrawal endand/or main body, prior to use. In addition, it may be advantageous tohave a tampon with one or more portions with improved fluid absorptioncharacteristics. Further, it may be desirable to provide a tampon thatis more comfortable for the user to insert. Further still, it would bedesirable to provide an apparatus and/or method of making a tampon thatprovides a tampon with at least one relatively appealing portions. Itwould also be desirable to provide a tampon that is more comfortable forthe user to insert. Moreover, it would be desirable to provide a tamponwith improved absorption properties during use.

SUMMARY OF THE INVENTION

Embodiments of the invention address the foregoing and encompass atampon which may comprise a compressed pledget of absorbent material.The tampon may have a body portion and a longitudinal axis, wherein thetampon may include at least one patterned impression with one or moredesign elements oriented substantially perpendicular to the longitudinalaxis. The compressed pledget may have been compressed into a tampon moldhaving a mold cavity for receiving the compressed pledget of absorbentmaterial, wherein the tampon mold may include at least one patternoriented substantially perpendicular to the longitudinal axis of thecompressed pledget, wherein the at least one pattern may include atleast one smooth lead in portion to one or more design elements.

According to another aspect of this invention, an apparatus for making atampon is provided and may include a compression machine for receivingand compressing an uncompressed pledget of absorbent material so as toform a compressed pledget. The apparatus may also include a tampon moldhaving a mold cavity for receiving the compressed pledget of absorbentmaterial, wherein the tampon mold may include at least one patternoriented substantially perpendicular to the longitudinal axis of thecompressed pledget, wherein the at least one pattern may include atleast one lead in portion to one or more design elements. Furthermore,the apparatus may include a compression member for pushing thecompressed pledget into the tampon mold cavity.

Other embodiments, aspects, features, and advantages of the inventionmay be apparent from reading the following detailed description,drawings, and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an uncompressed pledget of absorbentmaterial for use in making a tampon in accordance with an embodiment ofthe present invention.

FIG. 2 is a plan view of a tampon forming apparatus, in accordance withan embodiment of the present invention, with the tampon compressionmachine in an open position.

FIG. 3 is a perspective view of the tampon compression machine of FIG. 2in an open position.

FIG. 4 is a perspective view of the tampon compression machine of FIG. 2in a compression position.

FIG. 5 is a partial perspective view of the compression member whichforms part of the tampon forming apparatus in FIG. 2.

FIG. 6 is a perspective view of a split cavity tampon mold which is partof the tampon forming apparatus illustrated in FIG. 2.

FIG. 7 is an upper view of a tampon split mold cavity in accordance withan embodiment of the invention.

FIG. 8 is a lower cross-sectional view of the tampon split mold cavityin FIG. 7.

FIG. 9 is a lower cross-sectional view of another example tampon splitmold cavity in accordance with an embodiment of the invention.

FIG. 10 is partial perspective view of the tampon forming apparatus inFIG. 2 with the tampon compression machine in open position and anuncompressed pledget in the tampon compression machine cavity.

FIG. 11 is a partial perspective view of the tampon forming apparatus ofFIG. 2 with the tampon compression machine in a final compressionposition and a compressed pledget in the compression machine cavity.

FIG. 12 is a partial perspective view of the tampon forming apparatus ofFIG. 2 with a compressed pledget in the tampon split mold cavity.

FIG. 13 is a detail view of a compressed pledget being forced into anexample tampon split mold cavity in accordance with an embodiment of theinvention.

FIGS. 14-16 are perspective views of example tampons made in accordancewith various embodiments of the invention.

FIGS. 17-21 are perspective views of example tampon patterns made inaccordance with various embodiments of this invention.

DETAILED DESCRIPTION OF THE INVENTION

As summarized above, this invention may encompass a tampon and anapparatus for making such a tampon. As will be explained in more detailbelow, tampons in accordance with embodiments of the invention may bemade by compressing an uncompressed pledget of absorbent material with atampon forming apparatus having a relatively smooth lead in portion todesign elements so that patterned impressions substantiallyperpendicular to the longitudinal axis of the tampon can be formed inthe surface of the tampon. Pushing the compressed pledget over therelatively smooth lead in portion in the longitudinal direction of thecompressed pledget during compression in the direction of the pledgetlength may permit the material to avoid impinging against any relativelysharp surfaces. As a result, tampons made in accordance with certainembodiments of this invention may have an attractive surface appearanceor improved re-expansion abilities, or both. Further, having arelatively smooth trailing or transition portion leading or trailingaway from the pattern may aid pattern definition.

Section A below describes terms for assisting the reader inunderstanding features of the invention, but not introducing limitationsin the terms inconsistent with the context with which they are used inthe specification. Section B is a detailed description of the drawingsillustrating an apparatus in accordance with embodiments of thisinvention. Section C describes methods of manufacturing tampons inaccordance with embodiments of this invention and Section D describestampons made in accordance with this invention.

A. Terms

As used herein, “compression” refers to the process of pressing,squeezing, compacting or otherwise manipulating the size, shape, and/orvolume of a material to obtain a tampon having a vaginally insertableshape. The term “compressed” refers to the state of a material ormaterials subsequent to compression. Conversely, the term “uncompressed”refers to the state of a material or materials prior to compression. Theterm “compressible” is the ability of a material to undergo compression.

As used herein, “mold” refers to a structure for shaping a pledgetduring compression and/or retaining the shape for a compressed pledgetsubsequent to compression during the stabilization process. Molds havean inner surface defining an inner cavity and an outer surface. Theinner cavity is structured to define or mirror the shape of thecompressed absorbent pledget. Thus, in some embodiments the pledgetconforms to the shape of the inner cavity of the mold by a restrainingforce to result in a self-sustaining shape and is retained in the innercavity during the stabilization process. The inner cavity may beprofiled to achieve any shape known in the art including, but notlimited to, cylindrical, oval, rectangular, triangular, trapezoidal,semi-circular, hourglass, serpentine or other suitable shapes. The outersurface of the mold is the surface external to the inner surface and canbe profiled or shaped in any manner, such as, rectangular, cylindricalor oblong. The mold may comprise one or more members. Suitable moldsused in embodiments of the invention may include, but may not be limitedto unitary molds, comprising one member, and split cavity molds. Splitcavity molds may be used when producing shaped tampons, such as thosedisclosed in U.S. patent application Ser. No. 10/150,050 entitled“Substantially Serpentine Shaped Tampon,” and U.S. patent applicationSer. No. 10/150,055, entitled “Shaped Tampon,” both filed on Mar. 18,2002.

As used herein the term “pledget” refers to a construction of absorbentmaterial prior to the compression of such construction into a tampon.

As used herein, “self-sustaining” is a measure of the degree orsufficiency to which the tampon retains its compressed form afterstabilization such that in the subsequent absence of external forces,the resulting tampon will tend to retain its vaginally insertable shapeand size. It will be understood by one of skill in the art that thisself-sustaining form need not, and may not persist during actual use ofthe tampon. That is, once the tampon is inserted into the vagina orother body cavity and begins to acquire fluid, the tampon will begin toexpand and may lose its self-sustaining form.

The term “shaped tampons,” as used herein, refers to compressed pledgetshaving either a substantially serpentine shape, an “undercut” or“waist,” or a non-uniform cross-section traversing from the insertionend to the withdrawal end of the tampon. The phrase “substantiallyserpentine” refers to a non-linear dimension between any two pointsspaced at least about 5 mm apart. The term “undercut” refers to tamponshaving a protuberance or indentation that impedes the withdrawal from aunitary mold. For example, shaped tampons may be hourglass shaped havingat least one perimeter in the center of the tampon or “waist” that isless than both an insertion end perimeter and a withdrawal endperimeter.

As used herein, the term “split cavity mold” is a mold comprised of twoor more members that when brought together complete the inner cavity ofthe mold. Each member of the split cavity mold comprises at least aportion of the inner surface that when brought together or closedcompletes the mold structure. The split cavity mold is designed suchthat at least two or more of the mold members can be at least partiallyseparated, if not fully separated, typically after the tampon hasacquired a self-sustaining shape, to expand the cavity volumecircumscribed by the inner surface(s) thus permitting the easier removalof the tampon from the mold. Partial separation can occur when only aportion of two mold members are separated while other portions of thetwo mold members remain in contact. Where each member's inner surfaceportion joins the inner surface portion of another member, those pointsof adjacency can define a straight line, a curve, or another seam of anyconvoluted intersection or seam of any regular or irregular form. Theelements of the split cavity in some embodiments may be held inappropriate position relative to each other by linking elements of anyform including bars, rods, linked cams, chains, cables, wires, wedges,screws, etc.

The term “stabilized,” as used herein, refers to a tampon in aself-sustaining state wherein it has overcome the natural tendency tore-expand to the original size, shape and volume of the absorbentmaterial and overwrap, which comprise the pledget.

As used herein the term “tampon,” refers to any type of absorbentstructure that is inserted into the vaginal canal or other body cavitiesfor the absorption of fluid therefrom, to aid in wound healing, or forthe delivery of active materials, such as medicaments, or moisture. Thetampon may be compressed into a generally cylindrical configuration inthe radial direction, axially along the longitudinal axis or in both theradial and axial directions. While the tampon may be compressed into asubstantially cylindrical configuration, other shapes are possible.These may include shapes having a cross section that may be described asoval, rectangular, triangular, trapezoidal, semi-circular, hourglass,serpentine, or other suitable shapes. Tampons have an insertion end,withdrawal end, a length, a width, a longitudinal axis and a radialaxis. The tampon's length can be measured from the insertion end to thewithdrawal end along the longitudinal axis. A typical compressed tamponfor human use is within a range from about 30 to about 60 mm in length.A tampon may be straight or non-linear in shape, such as curved alongthe longitudinal axis. A typical compressed tampon is within a rangefrom about 8 to about 20 mm wide. The width of a tampon, unlessotherwise stated in the specification, corresponds to the distanceacross the largest cross-section, along the length of the tampon andperpendicular to the longitudinal axis of the tampon.

The term “vaginal cavity,” “within the vagina,” and “vaginal interior,”as used herein, are intended to be synonymous and refer to the internalgenitalia of the mammalian female in the pudendal region of the body.The term “vaginal cavity” as used herein is intended to refer to thespace located between the introitus of the vagina (sometimes referred toas the sphincter of the vagina or hymeneal ring), and the cervix. Theterms “vaginal cavity,” “within the vagina” and “vaginal interior,” donot include the interlabial space, the floor of vestibule or theexternally visible genitalia.

As used herein, “cm” is centimeter, “g” is grams, “g/m²” is grams permeter squared, “L” is liters, “L/s” is liters per second, “mL” ismilliliters , “mm” is millimeters, “min” is minutes, “rpm” rate perminute, and “s” is seconds.

As used herein, the “tampon compression machine” is a machine assemblythat includes parts that may compress a pledget. Typically a pledgetcompressed in the tampon compression machine is then transferred to amold for final shaping into a self-sustaining form of a vaginallyinsertable shape where, the mold may further compress parts of thepledget beyond that which the tampon compression machine accomplishedprior.

As used herein, the “compression member” is any member that can be usedto compress a pledget. It can also function to transfer a compressedpledget.

As used herein, “actuating” is any force delivered by an electric motor,mechanical transmission, pneumatically, linear drive, manual, and/orhydraulic.

As used herein, a “high aspect ratio shape” is any shape in which thewidth is greater than the thickness of the shape. The shape may notnecessarily contain any defined circles, arcs, or cross-sectionalportions.

As used herein, a “pattern,” “pattern structure,” “pattern die element,”or “pattern element” is a predefined shape formed in a mold that iscapable of forming a corresponding patterned impression on a surface ofa tampon pledget.

As used herein, a “base portion” is a portion of a mold without apattern.

As used herein, a “lead in portion” is a portion of a mold immediatelyadjacent to a pattern associated with a mold and is on an opposing sideof the pattern from a trailing portion. A “lead in portion” is generallythe portion of the mold where a pledget enters the mold, however it ispossible that a pledget can enter the mold at a “trailing portion” ofthe mold in accordance with certain embodiments of the invention.

As used herein, a “trailing portion” is a portion of a mold immediatelyadjacent to a pattern associated with a mold and is on an opposing sideof the pattern from the lead in portion.

B. Tampons and Tampon Manufacturing Apparatus

Turning to FIG. 1, an uncompressed pledget 10 of absorbent material 12is illustrated. The uncompressed pledget 10 may be compressed to form atampon in accordance with an embodiment of this invention. Theuncompressed pledget 10 extends from an insertion end 14 to a withdrawalend 16 with opposing sides 18 and 20 extending from the insertion end 14to the withdrawal end 16. A withdrawal cord or drawstring 22 may beconnected to and extend from the withdrawal end 16 of the uncompressedpledget 10.

Although the uncompressed pledget 10 is illustrated as having agenerally square or rectangular shape, the uncompressed pledget 10 canhave a variety of shapes including, but not limited to, oval, round,chevron, square, rectangular, and the like. The uncompressed pledget 10may have a length L1 extending from the insertion end 14 to thewithdrawal end 16 of the uncompressed pledget 10, a width W1 extendingfrom the one side 18 of the uncompressed pledget 10 to the other side 20and perpendicularly to the length L1, and a thickness T1 extendingperpendicularly to both the length L1 and width W1 of the uncompressedpledget 10.

The absorbent material 12 of the uncompressed pledget 10 may beconstructed from a wide variety of liquid absorbing materials commonlyused in absorbent articles. Such materials include but are not limitedto rayon (such as GALAXY rayon, SARILLE L rayon both available fromAccordis Kelheim GmbH of Kelheim, Germany), cotton, folded tissues,woven materials, nonwoven webs, synthetic and/or natural fibers orsheathing, comminuted wood pulp which is generally referred to asairfelt, or combinations of these materials. Other materials that may beincorporated into the pledget 10 include peat moss, absorbent foams(such as those disclosed in U.S. Pat. No. 3,994,298 issued to Desmaraison Nov. 30, 1976 and U.S. Pat. No. 5,795,921 issued to Dyer, et al.),capillary channel fibers (such as those disclosed in U.S. Pat. No.5,356,405 issued to Thompson, et al. issued on Oct. 18, 1994), highcapacity fibers (such as those disclosed U.S. Pat. No. 4,044,766 issuedto Kaczmarck, et al. on Aug. 30, 1994), and super absorbent polymers orabsorbent gelling materials (such as those disclosed in U.S. Pat. No.5,830,543 issued to Miyake, et al. on Nov. 3, 1998). A more detaileddescription of liquid absorbing materials shapes and dimensions can befound in U.S. Pat. No. 6,740,070 to Raymond Agyapong.

The uncompressed pledget 10 may optionally include an overwrapcomprising materials such as rayon, cotton, bicomponent fibers,polyethylene, polypropylene, other suitable natural or synthetic fibersknown in the art, and mixtures thereof. In some embodiments, theuncompressed pledget 10 has a nonwoven overwrap comprised of bicomponentfibers that have a polypropylene core surrounded by polyethylenemanufactured by Vliesstoffwerke Christian Heinrich Sandler GmbH andCompany KG (Schwarzenbach/Salle Germany) under the trade name SASB31812000. In other embodiments, the tampon may comprise a nonwovenoverwrap of a hydro entangled blend of 50% rayon, 50% polyesteravailable as BBA 140027 produced by BBA Corporation of South Carolina,US. The overwraps may be treated to hydrophilic, hydrophobic, wicking ornonwicking.

The uncompressed pledget 10 may optionally include a secondary absorbentmember, an additional overwrap, a skirt portion and/or an applicator. Awithdrawal cord 22 may be attached to the uncompressed pledget 10 andmay be made of any suitable material in the prior art such as cotton andrayon. U.S. Pat. No. 6,258,075 issued to Taylor et al. describes avariety of secondary absorbent members for use in pledgets. An exampleof a skirt portion is disclosed in U.S. Pat. No. 6,840,927 to MargaretHasse.

A tampon forming apparatus 30 for making tampons in accordance with anembodiment of this invention is illustrated in FIGS. 2-9. The tamponforming apparatus 30 may generally comprise a tampon compression machine32 for initially compressing the uncompressed pledget 10 of absorbentmaterial to form a compressed pledget 33, a mold 34 (in this case shownas a split cavity mold) for receiving the compressed pledget 33 andsetting the compressed pledget 33 in a self-sustaining shape, and acompression member 35 for pushing the compressed pledget 33 into thesplit cavity mold 34. In other embodiments, other types of molds such asa unitary or single piece mold can be used instead of a split cavitymold.

The tampon compression machine 32 may comprise a u-shaped anvil 36, bestshown in FIGS. 3 and 4. The tampon compression machine 32 may comprise atop plate 38 and a juxtaposed bottom plate 40 extending from an end wall41 connecting the top and bottom plates 38 and 40 to an open end 42thereby forming a channel 44 between the top and bottom plates 38 and40. The channel 44 may extend from an inlet end 46 to a discharge end 48of the anvil 36. The tampon compression machine 32 may also comprise adie 50 comprising a solid plate 52 extending from a leading end 54 to atrailing end 56 and an actuating rod 58 connected to the trailing end 56for reciprocating the die 50 within the channel 44 of the anvil 36. Theleading end 54 of the die 50 and the top and bottom plates 38 and 40 andend wall 41 of the anvil 36 may form a compression machine cavity 60within the channel 44 of the anvil 36 for receiving the uncompressedpledget 10. The die 50 may compress the uncompressed pledget 10 in thecompression machine cavity to form the compressed pledget 33.

In certain embodiments, opposing plates 38 and 40 with end walls onopposing ends may move relative to each other and thereby compress theuncompressed pledget 10. Other configurations for the compressionmachine 32 for carrying out the functions described herein will beapparent to those skilled in the art from reading the details of thisspecification.

The compression machine cavity 60 of the tampon compression machine 32may have an oval cross sectional shape as illustrated in FIGS. 3 and 4,but it should be understood that the compression machine cavity 60 mayhave other shapes as well including, but not limited to, round, square,and rectangular cross-sectional shapes. When in an open configuration asillustrated in FIG. 3, the compression machine cavity 60 may have alength L2 extending from the inlet end 46 of the anvil 36 of thedischarge end 48, a width W2 extending from the interior of the anvilend wall 41 to the leading end 54 of the die 50 and perpendicular to thelength L2, and a thickness T2 extending from the interior of the topplate 38 of the anvil 36 to the bottom plate 40 perpendicular both tothe length L2 and width W2 of the compression machine cavity 60. In someembodiments, the width W2 of the compression machine cavity 60 when thecompression machine cavity is in an open configuration may be close toor greater than the width W2 of the uncompressed pledget 10. In certainembodiments, the length L2 of the compression machine cavity 60 may alsobe close to or greater than the length L1 of the uncompressed pledget10.

When in a compression configuration as illustrated in FIG. 4, thecompression machine cavity 60 may have a length L3 which is the same asthe length L2 in the open configuration and a thickness T3 which is samethickness as T2 in the open configuration, but may have a width W3 whichmay be substantially less than the width W2 of the compression machinecavity 60 in the open configuration and may be substantially less thanthe width W1 of the uncompressed pledget 10. In certain embodiments whenthe uncompressed pledget 10 is compressed in the tampon compressionmachine 32, the compressed pledget 33 may adopt the cross-sectionalshape and width and thickness of the compression machine cavity 60 inthe compressed configuration. Thus, the compressed pledget 33 may have awidth of W3 and a thickness of T3. The manner of actuation of the die 50within the anvil channel 44 to compress the pledget 10 may be by anysuitable means to drive the actuating rod 58.

The degree of compression of the uncompressed pledget 10 in thecompression machine cavity 60 in the widthwise direction may be a majorcomponent of the compression. In accordance with certain embodiments ofthis invention, the major compression of the uncompressed pledget in thecompression machine cavity 60 in the widthwise direction is within arange from about 65% to about 90% of the original width of theuncompressed pledget 10. The degree of compression of the uncompressedpledget 10 in the thickness and lengthwise directions may be a minorcomponent of the compression and, in accordance with certain embodimentsof this invention, the minor compression of the uncompressed pledget 10in the compression machine cavity 60 in the thickness and lengthwisedirections may be no more than about 40% of the original width of theuncompressed pledget 10. In accordance with certain embodiments of thisinvention, the major compression of the uncompressed pledget 10 in thecompression machine cavity 60 in the widthwise direction may be fromabout 75% to about 85% of the original width of the uncompressed pledget10 and the minor compression of the uncompressed pledget 10 in thecompression machine cavity 60 in the thickness and lengthwise directionsmay be no more than about 30% of the original width of the uncompressedpledget 10. It should be understood that it is contemplated in certainembodiments of the invention that there may be no compression of theuncompressed pledget 10 in the lengthwise and/or thickness directions.

As shown in FIG. 6, the mold 34, in this case a split cavity mold, maygenerally comprise a first half cavity mold plate 64 and a second halfcavity mold plate 66 which, when joined together in juxtaposed fashion,form the split cavity mold 34 with a mold cavity 68 extending from aninlet end 70 of the mold 34 to a distal end 72 of the mold 34. Althougha split cavity mold 34 is illustrated in FIG. 6, it should be understoodthat other types of mold structures may be used as well. Examples of asplit mold cavity with an associated first half cavity mold plate and asecond half cavity mold plate are illustrated in FIGS. 7-9 described ingreater detail below. Split cavity mold structures are disclosed indetail U.S. Pat. No. 7,047,608 to Sageser, et al. and pending U.S.patent application Ser. No. 10/887,645 entitled “Compressed, GasStabilized Tampon Having Multiple Folds” filed on Jul. 9, 2004.

The mold cavity 68 of the mold 34 may generally have a cross-sectionalshape similar to the cross-sectional shape of the compression machinecavity 60 when in the compressed configuration. Furthermore, the moldcavity 68 may have a length L4 extending from the inlet end 70 to adistal end 72 of the mold cavity, a width W4 extending substantiallyperpendicularly to the mold cavity length L4, and a thickness T4extending substantially perpendicularly to both the length L4 and widthW4 of the mold cavity 68. In certain embodiments, the width W4 andthickness T4 of the mold cavity 68 may be close to the width W3 andthickness T3 of the compression machine cavity 60 when in the compressedconfiguration. Because cross-sectional shape and dimensions of thecompression machine cavity 60 and the compressed configuration are verysimilar to the cross-sectional shape and dimensions of the mold cavity68, the compressed pledget 33 may not expand or otherwise change shapesignificantly when inserted directly from the compression machine cavity60 into the mold cavity 68.

In certain embodiments, the mold 34 may include one or more patterns orpattern die elements with at least one design element including at leastone lead in portion to the at least one design element, which may formcorresponding patterned impressions on the exterior surface of acompressed pledget. Examples of patterns, pattern die elements, anddesign elements which may be associated with a mold 34 are describedwith respect to FIGS. 7-9.

As shown in FIG. 5, the compression member 35 may comprise an actuatingrod 74 and a head 76 connected to the actuating rod 74 for contactingthe compressed pledget 33 to push the compressed pledget 33 from thecompression machine cavity 60 into the mold cavity 68. Thecross-sectional shape of the compression member head 76 may be similarto and, in certain embodiments, substantially identical to thecross-sectional shape of the compression machine cavity 60 in thecompressed configuration and the cross-sectional configuration of themold cavity 68. In certain embodiments, the compression member head 76may have a width W5 and a thickness T5 extending perpendicularly to thehead width. In certain embodiments, the compression member head 76 mayhave another geometry, configuration, or shape. For example, acompression member head, such as 76, may have a contoured shape with apattern for impressing a corresponding contoured shape and patternedimpression in a portion of the compressed pledget, such as 33.

The compression member head 76 may have a slot 78 therein for receivingthe withdrawal cord 22 of the compressed pledget 33 so that thewithdrawal cord is not cut by the compression member head 76 when thecompression member head 76 transfers the compressed pledget 33 into themold cavity 68.

FIG. 7 is an upper view of an example tampon split mold cavity for asplit cavity mold in accordance with an embodiment of the invention. Inthe embodiment shown in FIG. 7, a first half cavity mold plate 64 mayinclude one or more patterns or pattern die elements 80 for formingconcave-shaped pattern impressions. The patterns or pattern die elements80 in this example may be convex-shaped, and may include a series ofthree similarly shaped chevron-shaped pattern die elements 82, 84, 86oriented substantially or nearly perpendicular to the longitudinal axisof the split cavity mold or associated first half cavity mold plate. Thechevron-shaped pattern die elements 82, 84, 86 may provide correspondingchevron-shaped patterned impressions oriented substantially or nearlyperpendicular to the longitudinal axis of the compressed pledget, suchas 33, after the compressed pledget becomes in substantial contact withthe pattern die elements 82, 84, 86. Generally, a suitable pattern orpattern die element may include at least one design element orientedsubstantially or nearly perpendicular to the longitudinal axis of themold or associated first or second half cavity mold plate, if in a splitcavity mold. In other embodiments, suitable patterns or pattern dieelements may include, but is not limited to, convex or concave-shapedelements, combinations of convex and concave-shaped elements, lines,chevrons, rain drops, peanuts, waves, dimples, concentric circles,cross-hatching, stars, polygons, triangles, rings, lines, rectangles,petals, ellipsoids, tear drops, letters, or waves.

Each of the patterns or pattern die elements 82, 84, 86 may include alead in portion 88 and a trailing portion 90. The lead in portion 88 maybe adjacent to a leading edge 92 of each of the pattern die elements 82,84, 86, and the trailing portion 90 may be adjacent to a trailing edge94 of the pattern die elements 82, 84, 86. As shown in the lowercross-sectional view of the first half cavity mold plate 64 in FIG. 8,the lead in portion 88 may be a relatively smooth surface that connectsbetween a base portion 96 of the plate 64 and a raised portion 98 of thepattern die element 82, 84, 86. Likewise, the trailing portion 90 may bea relatively smooth surface that connects between a raised portion 98 ofthe pattern die element 82, 84, 86 and a base portion 96 of the plate64.

FIG. 9 illustrates a lower cross-sectional view of a cavity mold plate100 with a pattern or pattern die element 102 for forming aconvex-shaped pattern impression. In this embodiment, the lead inportion 104 may be a relatively smooth surface that connects between abase portion 106 of the plate 100 and a depressed portion 108 of thepattern die element 102. Likewise, the trailing portion 110 may be arelatively smooth surface that connects between the depressed portion108 of the pattern die element 102 and a base portion 106 of the plate100.

In the embodiment of FIG. 8, the lead in portion 88 of the pattern dieelements 82, 84, 86 may be approximately 0.7 mm in length, the raisedportion 98 may be approximately 0.5 mm in height as measured from thebase portion 96 of the plate 64, and the trailing portion 90 may beapproximately 0.7 mm in length. In certain embodiments, a raised ordepressed portion may be range between approximately 0.25 mm toapproximately 4.0 mm in height with corresponding proportional changesto the lengths of the lead in portion and trailing portion associatedwith the pattern or patterned die element. In certain embodiments, thelength of the lead in portion may be approximately 1 to 3 times theheight of the pattern die element. That is, if the height of a lead inportion is approximately 1.0 mm, the length of the lead in portion maybe between approximately 1.0 to approximately 3.0 mm in length. Incertain embodiments, the lead in portion and trailing portion need notbe the same length.

Generally, a suitable lead in portion may be a relatively smooth surfacethat slopes upward or downward from a base portion of an associatedcavity mold plate to a raised or depressed portion of the plate.Likewise, a suitable trailing portion may be a relatively smooth surfacethat slopes upward or downward from a raised or depressed portion of anassociated cavity mold plate to a base portion of the plate. In anyinstance, a suitable lead in portion and trailing portion for a patternor pattern die element may provide a relatively smooth transitionbetween a base portion of the associated plate and a raised or depressedportion of the pattern or pattern die element. Note that the cavity moldplate 100 shown in FIGS. 7-9 is shown by way of example and may not beto scale.

In one exemplary use of a split cavity mold, the first half cavity moldplate 64 may be used in conjunction with a second half cavity mold plate66. When mounted together, the two plates 64, 66 may form a split cavitymold 34 for receiving a compressed pledget of absorbent material. In oneembodiment, a second half cavity mold plate may include one or morepatterns or pattern die elements, similar to pattern die elements 80,and such patterns or pattern die elements may be opposite or offset fromthe patterns or pattern die elements 80 associated with a first halfcavity mold plate. In another embodiment, a second half cavity moldplate may include different shaped patterns or pattern die elements thanthe patterns or pattern die elements associated with a first half cavitymold plate. In yet another embodiment, a first half cavity mold platemay include one or more patterns or pattern die elements that mayintersect or otherwise coordinate with one or more patterns or patterndie elements associated with a second half cavity mold plate.

In any instance, when a compressed pledget, such as 33, is introducedbetween the first half cavity mold plate 64 and the second half cavitymold plate 66, or the split cavity mold 34, the pledget material mayinitially flow over the base portion 96 of the plate 64. As noted above,other types of molds such as a unitary or single piece mold can be usedinstead of a split cavity mold. When the pledget material encounters thelead in portion 88, the pledget material may flow over the lead inportion 88 to the raised portion of the plate 66. The relatively smoothslope of the lead in portion 88 may assist the pledget material inmoving across the surface of the split cavity mold 34 between the baseportion 96 and the raised portion 98 with minimal tearing or damage tothe pledget material. The pledget material may then flow over the raisedportion of the plate 66 to the trailing portion 90, and flow over thetrailing portion 90 to the lower portion 96 of the plate 64. Therelatively smooth slope of the trailing portion 90 may assist thepledget material in moving across the surface of the mold 34 between theraised portion 98 and the base portion 96 with minimal or no tearing ordamage to the pledget material. In this manner, a compressed pledget maybe introduced into and pushed through the split cavity mold tofacilitate formation of various pattern impressions which may beoriented substantially or nearly perpendicular to the longitudinal axisof the compressed pledget with minimal or no tearing or damage to thepledget material or compressed pledget. An example of the movement ofthe pledget material with respect to example cavity mold plates is shownand described in detail in FIG. 13.

Examples of tampons with patterned impressions formed by a split cavitymold having patterns or pattern die elements oriented substantially ornearly perpendicular to the longitudinal axis of the compressed pledgetor tampon are shown and described with respect to FIGS. 14-16. Examplesof tampon patterns formed by mold having patterns or pattern dieelements oriented substantially or nearly perpendicular to thelongitudinal axis of a compressed pledget or tampon are shown anddescribed with respect to FIGS. 17-21.

Accordingly, the compressed pledget 33, the compression machine cavity60 in the compressed configuration, the mold cavity 68, and thecompression member head 76, each may have cross-sectional shapes anddimensions which are very similar. These close tolerances may help avoidtrapping of fibers from the compressed pledget 33 as the compressionmember head 76 transfers the compressed pledget into the mold cavity 60.Trapped fibers may create binding and shearing forces that may damagethe tampon forming apparatus 32 or tear or otherwise damage thecompressed pledget 33, or both. In certain embodiments, the compressedpledget 33, the compression machine cavity 60 in the compressedconfiguration, and the compression member head 76, each may havecross-sectional shapes and dimensions which are very dissimilar and, incertain embodiments, even substantially non-identical. In theseinstances, coordination between the compression member head 76 and thecompression machine cavity 60 should be controlled to minimize orotherwise prevent damage to the tampon forming apparatus 30 or thecompressed pledget 33, or both, when the compressed pledget 33 isremoved from the compression machine cavity 60.

According to certain embodiments, the compressed pledget 33 may beheated in the mold cavity 68 to impart a self-sustaining shape to thecompressed pledget 33 and resulting tampon. Methods of setting orstabilizing the tampon shape are well known and include heating thecompressed pledget 33 with steam as disclosed in U.S. patent applicationSer. No. 10/887,645 or thermal temperature gradient conduction ormicrowaving, as disclosed in U.S. Pat. No. 7,047,608.

A variety of materials may be used to make the components of the tamponforming apparatus 30. Suitable materials may be relatively rigid andinclude, but are not limited to stainless steel, and in the case ofmicrowave heat stabilization, microwave safe materials.

C. Method of Making Tampons

A tampon may be made in accordance with an embodiment of this inventionby first inserting the uncompressed pledget 10 in the open compressionmachine cavity 60 as shown in FIG. 10. As described hereinbefore, thethickness T1 of the uncompressed pledget 10 may be very close to thethickness T2 of the compression machine cavity 60 and the width W1 ofthe uncompressed pledget 10 may be close to or less than the width W2 ofthe compression machine cavity 60. The length L1 of the uncompressedpledget 10, however, may be less than the length L2 of the compressionmachine cavity 60.

According to certain embodiments, the thickness of the uncompressedpledget 10 can vary as can the particular dimensions of the compressionmachine cavity 60, mold cavity 68, and compression member head 76, but,according to certain embodiments, uncompressed pledget 10 thickness maygenerally range from about 5 to about 15 millimeters, or from about 5 toabout 12 millimeters, or from about 5 to about 9.8 millimeters.

The uncompressed pledget 10 may then be compressed in the compressionmachine cavity 60 by actuating the die 50 of a tampon compressionmachine 32 within the anvil channel 44 toward the end wall 41 of theanvil 36 until the compressed configuration illustrated in FIGS. 4 and11 is reached. The amount of force required to compress the pledget 10may vary but suitable forces typically are about 50 to about 1000 psi. Avariety of techniques for actuating the compression die 50 are wellknown and may include, but are not limited to a modified tamponcompression machine available from Tory Engineering Company, of Osaka,Japan. According to certain embodiments, the compressed pledget width W3is predetermined and the compression machine 32 compresses theuncompressed pledget 10 only to the compressed pledget width W3. Inaccordance with certain embodiments, methods for stopping thecompression applied by the die 50 may include, but are not limited to astop or détente structure for stopping forward movement of the die 50when the predetermined compressed pledget width W3 is reached orsuitable controls on the actuating mechanism for reciprocating the die50.

After compression in the tampon compression machine 32, the compressedpledget 33 may be ejected from the compression machine cavity 60 byactuating the compression member 35 so that the compression member head76 enters the inlet end 46 of the compression machine cavity and extendsthrough the compression machine cavity 60 forcing the compressed pledget33 through the inlet end 70 of the mold cavity 68.

When the compressed pledget 33 initially enters the mold cavity 68, thecompressed pledget 33 may be forced into the mold cavity 68 until thecompressed pledget 33 compacts against the distal end 72 of the moldcavity 68 and the compressed pledget 33 is completely within the moldcavity 68 as shown in FIG. 12.

FIG. 13 is a detail view of a compressed pledget being forced into anexample tampon split mold cavity in accordance with an embodiment of theinvention. In this example, a compressed pledget 112, similar to 33, isshown being introduced into a mold cavity 114, similar to 68, associatedwith a split cavity mold 116. The compressed pledget 112 may be forcedalong a base portion 118 of the mold cavity 114 and past one or morepattern die elements 120, 122, 124. When the external surface of thecompressed pledget 112 encounters a lead in portion 126, similar to 88in FIGS. 7-8, associated with pattern die elements 120, the pledgetmaterial may flow over the lead in portion 126 to a raised portion ofthe pattern die element 120. The relatively smooth slope of the lead inportion 126 may assist the pledget material in moving across the surfaceof the split cavity mold 116 between the base portion 118 and a raisedportion 128 of the pattern die element 120 with minimal tearing ordamage to the pledget material. The pledget material may then flow overthe raised portion 128 of the pattern die element 120 to a trailingportion 130 of the pattern die element 120, and flow over the trailingportion 130 to the base portion 118 of the split cavity mold 116. Therelatively smooth slope of the trailing portion 130 may assist thepledget material in moving across the surface of the split cavity mold116 between the raised portion 128 and the base portion 118 with minimalor no tearing or damage to the pledget material. In this manner, acompressed pledget may be introduced into and pushed through the splitcavity mold to facilitate formation of various pattern impressions whichmay be oriented substantially or nearly perpendicular to thelongitudinal axis of the compressed pledget with minimal or no tearingor damage to the pledget material or compressed pledget.

Generally, the compressed pledget 33 may be compressed by the tamponcompression machine 32 to a predefined size depending on the patterns orpattern die elements associated with the mold 34. In certain embodimentsfor forming convex-shaped pattern impressions on a tampon, thecompressed pledget 33 may be compressed to match or approximate thesmallest diameter of the mold cavity 68 or 114. When the compressedpledget 33 is forced into the mold cavity 68 or 114, the compressedpledget may expand slightly to fill the concave-shaped pattern dieelements associated with the mold 34. In certain embodiments for formingconcave-shaped pattern impressions on a tampon, the compressed pledget33 may be compressed to match or approximate the smallest diameter ofthe mold cavity 68 or 114. When the compressed pledget 33 is forced intothe mold cavity 68 or 114, the compressed pledget may move over the leadin portions and trailing portions of the convex-shaped pattern dieelements associated with the mold 34. In certain embodiments for formingoffset patterned impressions on opposing lateral sides of a tampon, suchas offset convex-shaped patterned impressions, the compressed pledget 33may be compressed to match or approximate the largest diameter of themold cavity 68 or 114. That is, the diameter of the mold cavity at apoint which includes only one pattern die element. In certain tamponembodiments with offset concave-shaped patterned impressions on opposinglateral sides of a tampon, the compressed pledget 33 may be compressedto match or approximate the smallest diameter of the mold cavity 68 or114.

In one embodiment, the compression member head 76 may include one ormore patterns or pattern die elements, such that when the compressionmember head 76 forces the compressed pledget into the mold cavity 68 or114, a pattern impression corresponding to the one or more patterns orpattern die elements may be formed adjacent to an end of the compressedpledget.

In another embodiment, the compression member head 76 may provide asuitable amount of compression on the compressed pledget within the moldcavity 68 or 114 to force the opposing end of the compressed pledgetinto a mold with one or more patterns or pattern die elements adjacentto the opposing end of the compressed pledget. In certain embodiments,pattern impressions such as a tapered tip or blunt tip can be formed atan opposing end of the compressed pledget. In other embodiments, patternimpressions such as raindrop-shaped elements crossing over from onelateral side to another lateral side of the compressed pledget can beformed adjacent to the opposing end of the compressed pledget.

In any instance, once in the mold cavity 68, the compressed pledget 33may be stabilized by conventional heat treatment and then ejected fromthe mold cavity by conventional means such as by pulling the withdrawalcord 22, manually or mechanically by pushing, grasping, hooking,picking, or clamping the tampon and withdrawing it from the mold, orvacuum withdrawal, or the like. Suitable methods of tampon removal fromthe mold are described in U.S. Pat. No. 7,047,608.

D. Tampons

Tampons made by the foregoing method may have patterned impressionswhich may be substantially or nearly perpendicular to a longitudinalaxis of the tampon created in the outer surface of the tampon. Incertain embodiments, tampons made in accordance with the foregoingmethod may have a width to thickness ratio of approximately 1.0:1.0 toapproximately 1.8:1.0.

Example tampons and tampon patterns made in accordance with embodimentsof this invention are illustrated in FIGS. 14-21. The tampon 132illustrated in FIG. 14 is made according to an embodiment of thisinvention and may have a plurality of patterned impressions along theexterior surface of the tampon 132. In this embodiment, the patternedimpressions may be a series of three convex, chevron-shaped ribelements, which may be generally perpendicular to a longitudinal axis ofthe tampon 132. In certain embodiments, the patterned impressions may beapproximately 0.5 mm in height above or below the exterior surface ofthe tampon, for instance, a patterned impression can be a convex-shapedelement approximately 0.5 mm in height above the exterior surface of thetampon.

The tampon 132 as illustrated in FIG. 14, the tampon 134 in FIGS. 15 and16, the tampon pattern 136 in FIGS. 17 and 18, the tampon pattern 138 inFIG. 19, the tampon pattern 140 in FIGS. 20 and 21, and the tampons andtampon patterns made according to embodiments of this invention can bemade by applying a compression to the uncompressed pledget 10, shown inFIG. 1, and forcing the compressed pledget 33 into a mold cavity,wherein the mold cavity comprises at least one pattern orientedsubstantially perpendicular to the longitudinal axis of the compressedpledget, wherein the at least one pattern comprises at least one smoothlead in portion associated with one or more design elements. This isexplained in detail in the foregoing description of the tampon formingapparatus 30. Prior art processes which manufacture tampons by applyingcompression to a compressed pledget within a mold cavity with generallylongitudinally-oriented patterns are distinct from the process of thisinvention.

In the embodiment of a tampon shown in FIGS. 15 and 16, the tampon 134may have patterned impressions on opposing lateral sides including threeconcave, chevron-shaped rib elements, which may be generallyperpendicular to a longitudinal axis of the tampon 134. As shown in thisexample, the patterned impressions on one lateral side of the tampon 134may be offset from similar shaped pattern impression on an opposing oranother lateral side of the tampon 134. In certain embodiments, thepatterned impressions may be approximately 0.5 mm in height above orbelow the exterior surface of the tampon.

In the embodiment of a tampon pattern shown in FIGS. 17-18, a taperedtip tampon having a pattern such as 136 may have patterned impressionson four lateral sides of the tampon including concave, peanut-shapedelements on the relatively thinner lateral sides and the concave, andopen raindrop-shaped elements on the relatively wider lateral sides,wherein the open raindrop-shaped elements cross over the upper portionor top of the tampon. Some or all of the peanut-shaped andraindrop-shaped elements may have portions that are generallyperpendicular to a longitudinal axis of the associated tampon. Incertain embodiments, the patterned impressions may be approximately 0.5mm in height above or below the exterior surface of the associatedtampon, and may decrease to approximately 0.25 mm in height above orbelow the exterior surface of the tampon as the elements cross over theupper portion or top of the tampon.

In the embodiment of a tampon pattern shown in FIG. 19, a tapered tiptampon having a tampon pattern such as 138 may have patternedimpressions on four lateral sides of the tampon, including concave,peanut-shaped elements on the relatively thinner lateral sides and theconcave, raindrop-shaped element on the relatively wider lateral sides,wherein some or all of the elements may have portions that are generallyperpendicular to a longitudinal axis of the tampon. In certainembodiments, the patterned impressions may be approximately 0.5 mm inheight above or below the exterior surface of the associated tampon, andmay decrease to approximately 0.25 mm in height above or below theexterior surface of the tampon towards the upper portion or top of thetampon.

In the embodiment of a tampon pattern shown in FIGS. 20-21, a blunt tiptampon having a tampon pattern such as 140 may have patternedimpressions on four lateral sides of the tampon, including concave,peanut-shaped elements on the relatively thinner lateral sides and theconcave, raindrop-shaped element on the relatively wider lateral sides,wherein some or all of the elements may have portions that are generallyperpendicular to a longitudinal axis of the tampon. In certainembodiments, the patterned impressions may be approximately 1.0 mm inheight above or below the exterior surface of the associated tampon, andmay decrease to approximately 0.5 mm in height above or below theexterior surface of the tampon towards the upper portion or top of thetampon.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

All documents cited in the Detailed Description of the Invention are, inrelevant part, incorporated herein by reference; the citation of anydocument is not to be construed as an admission that it is prior artwith respect to the present invention. To the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the invention have been illustrated anddescribed, it would be obvious to those skilled in the art that variousother changes and modifications can be made without departing from thescope of the invention. It is therefore intended to cover in theappended claims all such changes and modifications that are within thescope of this invention.

1. A tampon comprising a compressed pledget of absorbent material, thetampon having a body portion and a longitudinal axis, wherein the tamponcomprises at least one patterned impression comprising one or moredesign elements with a portion of the design element orientedsubstantially perpendicular to the longitudinal axis, wherein at leastone design element is formed by contact with at least one correspondingmold pattern comprising at least one lead in portion.
 2. The tampon ofclaim 1, wherein the one or more design elements comprise at least oneof the following: a concave-shape or a convex-shape, a combinationconcave and convex shape, lines, chevrons, rain drops, peanuts, waves,dimples, concentric circles, cross-hatching, stars, polygons, triangles,rings, lines, rectangles, petals, ellipsoids, tear drops, letters, orwaves.
 3. The tampon of claim 1, comprising a width to thickness ratioof approximately 1.0:1.0 to approximately 1.8:1.0.
 4. The tampon ofclaim 1, wherein the height or depth of the patterned impression isbetween approximately 0.25 mm to approximately 4.0 mm.
 5. The tampon ofclaim 1, wherein the at least one lead in portion comprises a lengthbetween approximately 1 to 3 times the height or depth of the pattern.6. The tampon of claim 1, wherein the at least one corresponding moldpattern further comprises at least one trailing portion.
 7. An apparatusfor making a tampon comprising: a compression machine for receiving andcompressing an uncompressed pledget of absorbent material so as to forma compressed pledget; a tampon mold having a mold cavity for receivingthe compressed pledget of absorbent material, wherein the tampon moldcomprises at least one pattern comprising at least a portion orientedsubstantially perpendicular to the longitudinal axis of the compressedpledget, wherein the at least one pattern comprises at least one lead inportion to one or more design elements; and a compression member forpushing the compressed pledget into the tampon mold cavity.
 8. Theapparatus of claim 7, wherein the at least one lead in portion comprisesa length between approximately 1 to 3 times the height or depth of thepattern.
 9. The apparatus of claim 7, wherein the at least one patterncomprises at least one trailing portion.
 10. The apparatus of claim 7,wherein the at least one pattern comprises one or more design elementscomprising at least one of the following: a concave-shape, aconvex-shape, a combination concave and convex shape, lines, chevrons,rain drops, peanuts, waves, dimples, concentric circles, cross-hatching,stars, polygons, triangles, rings, lines, rectangles, petals,ellipsoids, tear drops, letters, or waves.
 11. The apparatus of claim 7,wherein the at least one pattern comprises offset design elements onopposing sides of the mold cavity.
 12. The apparatus of claim 7, whereinthe at least one pattern is between approximately 0.25 mm toapproximately 4.0 mm in height or depth.
 13. The apparatus of claim 7,further comprising: a stabilization member for stabilizing thecompressed pledget prior to removing the compressed tampon from thetampon mold.
 14. The apparatus of claim 7, wherein the tampon mold canbe opened to preserve a corresponding pattern impression associated withthe compressed pledget.